Method of making a sea shell surfacing



United States Patent 3,007,270 METHOD OF MAKING A SEA SHELL SURFACING Walter R. Stewart, Van Nuys, Calif. N0 Drawing. Filed May 12, 1958, Ser. No. 734,422 5 Claims. (Cl. 4134) This invention relates to ornamental decorative surfacing comprised of Pla'cuna placenta, and certain techniques for the adaption and coloring of the same.

This surfacing is manufactured from sea shells, preferably the Pla cuna placenta, which is naturally thin and cornparatively flat.

In general, the treatment of these shells involves cleaning mechanically or with acid, heating to render them opaque and to alter the physical characteristics and color, applying them with proper adhesive to paper, cleaning them after subjecting them to pressure, finishing them with clear or tinted lacquer. Also, color alteration by organic or inorganic chemical means is provided. In addition, new techniques in application to concave or convex surfaces, forming a joint, devising new patterns for laying out the shells to be pressed, and new modifications of the press itself are provided herein for the purposes of producing an improved decorative surfacing. Lastly, a new method for the application of sheet material to any surface is explained.

Initially, raw shells are soaked in a solution of water and acid for the purpose of removing foreign matter. Acids found suitable for this purpose include hydrochloric and phosphoric.

Next, they are treated by submitting them to the heat of a temperature-controlled oven, rather than by exposing them to an open flame or other retort. Temperatures of 350 F. and 450 F. are required in order to render the shells opaque and evidence a silver or gold lustre, respectively.

In the event the finished surface desired is to have an etched texture, as provided by the natural exterior surface of Placun'a placenta, then the adhesive is applied to the smooth, internal surface. In the case of the new, etched variety, it is necessary that first quality shells be used and that the only cleaning effected on them be done by acid bath. Any mechanical scraping will destroy the natural etched surface of the shell.

In the event a deep silver, charcoal, or black hue is desired, the shells may, at this point, he bathed in a solution of silver nitrate. The time of immersion is determined by the depth of color desired. For a turquoise color, the solution should be of copper sulphate. Other inorganic solutions capable of dyeing the shells may be substituted similarly. The strength of these solutions may vary, but in the case of silver nitrate, a ratio of 1 part silver nitrate to 99 parts of distilled Water, has proven successful. To produce a deeper hue, simply increase the amount of inorganic dye and the time of immersion.

In using this new process, it is not necessary to immerse the shells at any time in any binder solution, such as sodium silicate. This step was formerly needed in order to prevent waste because of breakage. Under this improved method, new techniques are introduced which eliminate the breakage formerly sustained. Also, it is now no longer necessary to smash the individual shells flat in a hand-operated smasher. This new improved process does away entirely with shell fractures, and the material produced under this process will be virtually fracture-free.

Furthermore, this process is not limited to first quality shells, but may be used successfully to include all grades of Placuna placenta, without regard to size, discoloration, or other natural flaws, blisters, and other disfigurement. These lower grade shells, on the contrary, offer a Wide 3,%7,270 Patented Nov. 7, 1961 ice latitude of variety, texture, hue, and adaptation not heretofore available.

The ragged edges of the shell, at this point, may be trimmed by scraping with a hand chisel or razor-tool. Heretofore no attention has been given to rough or mutilated edges, and the end product has not been as uniform as is possible if trimming is done at this time. Also, this same razor-tool may be used to lift and remove from each shells internal surface the V-shaped hinge. Removal of this hinge, at this time, makes possible the most attractive and the fiattest possible end-product.

Also, if the thickness of the shell seems to be disadvantageous to the desirable characteristics of the end surfacing, this same razor-tool may be use-d to scrape the external surface, thereby removing any natural disfigurement, or thereby reducing the shells thickness. Scraping is done by stroking the shell with the blade, begin ning at the point over the hinge, and proceeding radially toward the thin outer edges. Any other direction will inevitably destroy the shell.

If the shell, to be used, is very heavy, it may now be soaked in water in order to make it more pliable. Thinner shells need not so be soaked. After the thinner shells are laid out in proper pattern, a damp cloth is used to cover them so that they will absorb moisture prior to pressing.

The technique of shell lay-out for decorative surfacing formerly was restricted to cutting the shells into rectangular shapes and setting them in a mosaic pattern, like a checker board, using an adhesive to keep them in place.

This improved process has found a superior, more beautiful technique for producing a decorative surfacing. First, the shells are laid out like shingles, resembling large fish scales, and they are then placed in a mechanical, hydraulic, pneumatic, or other press, or submitted to proper pressure, so that they are bonded together. The shells may be bonded to a sheet of heavy paper by using a casein glue. It is possible to substitute pure colorless lacquer, and thereby avoid the necessity of cleaning off the excess glue after the pressing operation. This latter technique is more successful with small panels, due to the rapid drying time of lacquer.

The shells may be bonded to Masonite or wood surfaces, with or without the heavy paper referred to above. -I have found, however, that the most practical method is to bond the shells directly on heavy paper, and then mount the desired size panel on proper backing afterwards.

Also, if the final desired shape is round, oval, or freeform, the layout of the shell may be varied to conform with these geometric patterns. In the case of round shapes, layout may begin by placing a single shell in the center, and then placing concentric rows around it, until the entire surface is covered. Ovals and free-forms may be covered similarly. The application of colored shells of the same or different hues may be used in order to provide a graduated color effect.

Heretofore, shells have ben laid out in mosaic effect. This technique includes submitting the formation to pressures of up to as much as 200 p.s.i. or more. Fractures are entirely prevented by placing a layer of pure gum rubber sheeting, /2 in thickness, above the upper surface of the desired formation. This rubber buffer accommodates the physical conformation of the shells and distributes the pressurm evenly over the entire surface. If a steel press is used, it is desirable to further cushion the formation with /2 thick sheets of plywood, one above and one below the shell formation. Pressings take from four to eight hours, depending on the type of adhesive used. If a. press Whose plates are thermally equipped is used, this pressing time is reduced substantially. The

3 most practical size for presses seems to be those whose beds meaure 4' x 8'.

In order to build a formation greater in size than the size of the press, the formation may be constructed in two or more parts, with the last rows of shells of the adjacent edges of the formations left partially unglued. Careful planning will permit, after the panels have been permanently installed, the installation of an additional connecting row of shells, thereby splicing the formations into one seamless, continuous sheet of shells. The shells used for splicing are coated with adhesive, placed in their proper position, covered with wax paper, and a layer of gum rubber and plywood, respectively, is nailed over them, the nails being used only when the shells must be held against the force of gravity. Later, after the shell has set, the paper, rubber and plywood are removed, and the nail holes covered over with a plastic pearl composition which completely heals the wound caused by the holding nails.

After the formation has been pressed, or is set and dry,

it may be cleaned of all excess glue with the application of warm water and a rough cloth. It is then permitted to dry.

' After it is dry, rough edges of shells making up the formation may be sanded smooth, either by hand or with a vibrating electrical sander, or both. It is once again cleaned off with a damp cloth, and permitted to dry. It is now ready for a coat of lacquer consisting of equal parts of lacquer and thinner. If further inspection does not reveal a perfectly smooth formation, it may again be sanded. If the formation is not to be tinted, it is next coated with a coat of lacquer, consisting of one part thinner and two parts lacquer.

If the formation appears satisfactory at this point, it is then completed with two coats of alcohol-proof waterwhite clear lacquer for silver shell, yellow lacquer for gold shells.

For tinting the formation, after the initial coat of lacquer, a second coat of clear lacquer which has been tinted appropriately is now applied. The tinting will be uniform and pleasing to the eye. After this coat has dried, a final coat of alcohol-proof clear lacquer is applied and the formation is completed.

An alternate finish for this material is liquid polyester lacquer which may be used in lieu of conventional lacquers. Polyester liquid plastic lacquer produces a smooth, unbroken, transparent surface which makes this material suitable for table and bar topping. In addition, dyes may be added to the liquid polyester lacquer, thereby producing a transparent, colored finishd.

Formerly, the methods of mounting materials was to adhere the shells to the backing directly and to nail the formations in place. This produced unsightly points where the nails were inserted. This new and improved method avoids this altogether. For mounting on plywood, contact glue is used and the formation is hammered into place with a rubber hammer. This hammer does not in any way mar the formation, and the installation is permanent. Another method is to adhere the formation to the proper backing with a suitable adhesive, and to place both the formation and the hacking into a press and apply pressure until the desired bond is secured.

This superior material may be applied to any surface on which this decorative surfacing is suitable or desired. It is particularly attractive when combined with direct or indirect illumination of either natural and/or artificial sources, thus revealing an unblemished mother-of-pearl effect.

The surfaces manufactured according to the invention may be used for a variety of purposes: for example, table tops, large sheets for walls and ceilings, spliced or not, cabinets, trays, bed headboards, bar tops, altars, place mats, shop windows, show cases, aquaria, frames, powder rooms, homes, stores, on aircraft, ships, trains, house trailers, automobiles, or other vehicles.

In order to join two surfaces on different planes, one surface is covered with the shell material and its edge is cut flush. The second surface is then covered and its edge is trimmed to overlap the other surface. By finishing with sandpaper and with the application of plastic pearl composition, this joint is finished easily and neatly. The end result is one of solid or slab-effect appearance.

I claim:

1. A method for manufacturing a decorative surfacing of Placuna placenta shells, said method comprising: cleaning said shells to remove foreign matter therefrom; heating said shells in a temperature controlled oven while said shells are subject to visual inspection; removing said shells from said oven as they are observed to acquire a desired metallic hue; securing said shells by an adhesive to a surface to be covered, said shells being assembled on said surface in an edge overlapping relationship; and applying substantial pressure to said assembled shells through resilient material so that the pressure applied will be substantially uniform and accommodate to the natural configuration of the individual shells, whereby a fiat, fixed surface is obtained.

2. A method for manufacturing a decorative surfacing of Placzma placenta shells as described in claim 1 wherein said shells are heated in said oven within the temperature range of 350 to 450 Fahrenheit and said assembled shells are subjected to pressure of at least 200 p.s.i.

3. A method for manufacturing a decorative surfacing of Placuna placenta shells as described in claim 1 wherein, after said shells have been heated, their natural hinges are removed to render them of more uniform thickness.

4. A method for manufacturing a decorative surfacing of Placuna placenta shells as described in claim 1 including the removal of excess adhesive material from said assembled shells after said shells have been subjected to said pressure, and the subsequent application of a transparent, protective coating to the exposed surface of said assembled shells.

5. A method for manufacturing a decorative surfacing of Placuna placenta shells as described in claim 1 wherein said shells are soaked in water to render them more pliable prior to their being assembled and subjected to pressure.

References Cited in the file of this patent UNITED STATES PATENTS par. 4.

Leland: Useful Arts and Handicrafts, vol. 4, pp. 157, published by Dawbarn & Ward Ltd., London 1902. 

1. A METHOD FOR MANUFACTURING A ECORATIVE SURFACING OF PLACUNA PLACENTA SHELLS, SAID METHOD COMPRISING CLEANING SAID SHELLS TO REMOVE FOREIGN MATTER THEREFORM; HEATING SAID SHELLS IN A TEMPERATURE CONTROLLED OVEN WHILE SAID SHELLS FROM ARE OBSERVED TO ING SAID SHELLS FROM SAID OVEN AS THEY AREOBSERVED ACQUIRE A DERIRED MATALLIC HUE; SECURING SAID SHELLS BY AN ADHESIVE TO A SURFACE TO BE COVERED SAID SHELLS BEING ASSEMBLED ON SAID SURFACE IN AN EDGE OVERLAPPING RELATIONSHIP; AND APPLYING SUBSTANTIAL PRESSURE TO SAID ASSEMBLED SHELLS THROUGH RESLIENT MATERIAL SO THAT THE PRESSURE APPLIED WILL BE SUBSTANTIALLY UNIFORM AND ACCOMMODATE TO THE NATURAL CONFIGURATION OF THE INDIVIDUAL SHELLS, WHEREBY A FLAT, FIXED SURFACE IS OBTAINED WHEREBY A FLAT, FIXED SURFACE IS OBTAINED. 